WO2002026458A1 - Composition de demoulage - Google Patents

Composition de demoulage Download PDF

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Publication number
WO2002026458A1
WO2002026458A1 PCT/AU2001/001211 AU0101211W WO0226458A1 WO 2002026458 A1 WO2002026458 A1 WO 2002026458A1 AU 0101211 W AU0101211 W AU 0101211W WO 0226458 A1 WO0226458 A1 WO 0226458A1
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WO
WIPO (PCT)
Prior art keywords
composition
mould release
vegetable
tallow
derived
Prior art date
Application number
PCT/AU2001/001211
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English (en)
Inventor
John Rosani
Original Assignee
Rosmar Australia Pty Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Rosmar Australia Pty Ltd filed Critical Rosmar Australia Pty Ltd
Priority to AU9349001A priority Critical patent/AU9349001A/xx
Priority to AU2001293490A priority patent/AU2001293490B2/en
Priority to NZ524964A priority patent/NZ524964A/en
Publication of WO2002026458A1 publication Critical patent/WO2002026458A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B7/00—Moulds; Cores; Mandrels
    • B28B7/38—Treating surfaces of moulds, cores, or mandrels to prevent sticking
    • B28B7/384—Treating agents

Definitions

  • the present invention relates to mould release compositions suitable for use with concrete moulds and to methods of using these compositions as mould release agents for concrete moulds.
  • the present invention relates to mould release compositions containing a boron containing component selected from Boric acid or a borate (a salt of boric acid) or a derivative thereof and mixtures thereof and hydrates thereof, with preferred borates containing either 1 , 2, 3 or 4 boron atoms and with the most preferred borate being borax (disodium tetraborate). It is found that compositions of this type have useful mould release properties whilst at the same time avoiding some of the difficulties associated with mould release compositions that are currently available.
  • mould release compositions have been used for a number of years in the construction industry and in the housing and garden supply industries. Indeed, compositions of this type are widely used in any industry in which fabrication of concrete articles is required.
  • the mould release compositions are generally applied to solid surfaces such as form work, moulds, pallets or other surfaces that come into contact with fresh concrete before it has cured.
  • these mould release compositions are applied to the surface to be treated either by spraying or painting of the contact surface of the material prior to concrete being bought into contact with the surface of the material (which occurs when concrete is poured into the mould).
  • the mould release composition then typically forms a thin layer on the surface treated and provides a layer between the pre-cured concrete and the material facilitating removal of the concrete from the material (or vis-versa) once the concrete has adequately cured.
  • mould release compositions provide acceptable release properties between the concrete and the material forming the mould (which is typically steel or another metallic substance although wooden, plastic and even concrete moulds may also be used).
  • An ideal mould release agent would therefore theoretically produce a clean stripping action (removal of the cured concrete from the mould) with a minimum of surface defects on the hardened concrete surface thus produced.
  • many known mould release compositions lead to surface defects on the finished surface of the concrete. Typical surface defects encountered with concrete moulds include stains, voids, bugholes and impaired concrete surface texture making it unsuitable for interfaced bonding.
  • mould release property is the most important property of any mould release composition
  • additional properties are also desirable.
  • the ideal release composition therefore, in addition to providing good mould release (stripability) should be a non-staining composition.
  • many known mould release agents can, at times, produce staining or discoloration of the end product concrete which is particularly undesirable in decorative applications.
  • the release composition should be non-corrosive to the surfaces to be treated and any other materials it comes into contact with whilst in use.
  • mould release compositions When these mould release compositions are applied, they are typically used in circumstances where a smooth exterior surface of the concrete material is required to be formed and further composition qualities are thus needed. Thus, the composition should not promote the formation of air pockets or cause interference with concrete coating treatments as this will lead to bugholes or voids. Whilst in many instances a smooth finish is not required in the construction industry per se due to the proportions of the materials that are fabricated, this property of mould release compositions is typically important for decorative concrete applications such as the use of concrete as a construction material for producing garden ornaments and the like. In these applications, the relative smoothness of the finished article is crucial to the ultimate product performance and, as such, the ability of the mould release composition to produce such a surface is important.
  • a number of the known mould release compositions typically contain, as a solvent or carrier, petroleum based hydrocarbon liquids. This is undesirable as the hydrocarbon solvents are known to cause dermatological problems if they come into contact with the skin of sensitive subjects. Contact of these materials with the eyes of workers can also be undesirable. These agents may also be undesirable as potential run off of the composition can lead to environmental pollution.
  • composition contains materials that are irritants.
  • compositions have a high vapour pressure (typical of hydrocarbons) leading to excessive fuming of the applied layer.
  • vapour pressure typically of hydrocarbons
  • many of the known mould release compositions in addition to hydrocarbons, contain environmentally unfriendly materials and are indeed hazardous in use.
  • many of the compositions contain salts of alkyl phosphonic acids and/or organic acids which can be severely irritating to the skin and eyes of any worker. This therefore potentially limits the ability to use these compositions especially where the treating of components is conducted in a confined space.
  • the present invention provides mould release compositions including a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, salts of boric acid (borates), derivatives of borates and mixtures and hydrates thereof.
  • the composition is preferably an aqueous based composition.
  • the boron containing component is preferably a borate or derivatives thereof.
  • the borate preferably contains 1 to 6, more preferably 1 to 4 boron atoms. The exact amount of borate to be utilised will be dependent on the other ingredients in the composition. On a molar scale, the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably
  • borate 0.002 to 0.5 moles, more preferably 0.006 to 0J moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 to 0.034 moles per litre of composition.
  • Particularly preferred amounts of borate are 0.033 moles, 0.026 moles, and 0.025 moles.
  • the preferred borate is disodium tetraborate or a hydrate thereof. On a weight percentage basis, these amounts correspond to the amount of borate present in the composition being preferably in the range 0.07 to 19 wt.% (w/w), more preferably in the range 0.2 to 3.8 wt.%, even more preferably 0.2 to 1.9 wt.%, more preferably 0.75% to
  • the invention provides mould release compositions including a borate and at least one organic component having a melting point below 100°C.
  • suitable organic components are alcohols and polyols.
  • Preferred alcohols and polyols for use in the mould release compositions of the present invention include glycol, propylene glycol, and glycerol.
  • Preferred other organic components also include oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters and mixtures and derivatives thereof.
  • Particularly preferred organic components are vegetable oil, tallow and lanolin.
  • the present invention provides a method of improving the release of concrete from a surface including coating said surface with a composition including a boron containing component selected from boric acid, derivatives of boric acid, borates, derivatives of borates, mixtures and hydrates thereof prior to contacting said surface with concrete.
  • a composition including a boron containing component selected from boric acid, derivatives of boric acid, borates, derivatives of borates, mixtures and hydrates thereof prior to contacting said surface with concrete.
  • the invention in yet a further aspect relates to a method for producing a concrete article, said method including the steps of a) providing a mould for said concrete article; b) applying a mould release composition including a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, mixtures and hydrates thereof to said mould; c) bringing concrete into contact with said mould; d) allowing said concrete to cure; e) removing the cured concrete article from said mould.
  • a mould release composition including a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, mixtures and hydrates thereof
  • the preferred boron containing component is a borate with disodium tetraborate (borax) being particularly preferred.
  • the invention provides a method of preparing a mould release composition, said method including the step of combining a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof with at least one organic component having a melting point below 100°C.
  • a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof with at least one organic component having a melting point below 100°C.
  • Preferred organic components are alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters and mixtures and derivatives thereof.
  • Particularly preferred organic components are vegetable oil, tallow and lanolin.
  • the boron containing component is first dissolved in water to form an aqueous solution prior to combining it with the organic component. It is also preferred that said step of combining occurs at elevated temperatures, preferably between 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. It is also preferred that said combining takes place with agitation, preferably sufficient agitation to produce an emulsion.
  • a building material typically composed of stone, sand, cement and water.
  • Cement Nominally any bonding material.
  • An example of a well-known cement is Portland cement.
  • Portland cement and allied cements are made from materials containing lime, aluminium and silica (e.g. limestone and clay) which are heated strongly in a kiln to form a clinker (consisting mainly of calcium silicates and aluminates).
  • the finely ground clinker undergoes complex hydration processes when mixed with water, setting and hardening to a glove- like material.
  • Tallow This term designates the fat from the fatty tissue of animals particularly cattle and sheep. It is generally available as beef tallow and as sheep or mutton tallow. It is also available as horse tallow although this is rarely available. Oleo stock is the highest grade of beef tallow.
  • composition of tallow may vary, it is generally seen as being (as glycerides): Oleic acid (37-43%), palmitic (24-32%), stearic (20-25%), myristic (3-6%), linoleic (2-3%). Minor constituents are generally seen as cholesterol, arachidonic, elaidic, and vaccenic acids.
  • the amount of water in tallow varies greatly depending on the source of the tallow.
  • the tallow can have a moisture content of up to 10% by weight although the tallow used herein was tested to have a moisture content of 1.15%.
  • reference to an amount of tallow refers to the amount on a dry mass basis (anhydrous basis).
  • the amount of H 2 O required will be reduced by the increase in moisture provided by the additional tallow.
  • Lanolin is the "fat-like" secretion of the sebaceous glands of sheep which is deposited onto the wool fibers. Chemically it is a wax rather than a fat, being a complex mixture of esters and polyesters of 33 high-molecular- weight alcohols and 36 fatty acids.
  • the alcohols are of three types: aliphatic alcohols, steroid alcohols, and triterpenoid alcohols; the acids are also of three types: saturated nonhydroxylated acids, unsaturated nonhydroxylated acids and hydroxylated acids.
  • Liquid lanolin is rich in low molecular weight, branched aliphatic acids and alcohols while waxy lanolin is rich in high molecular weight, straight-chain acids and alcohols.
  • Lanolin contains a variable water content which can be as high as 25-30%.
  • the lanolin employed in the present formulations had a water content of 1.7%.
  • the amounts of lanolin referred to herein refer to the amount of lanolin required on a dry mass basis (anhydrous). It is a yellowish-white unctuous mass with a slight odor. It is practically insoluble in water but is soluble in chloroform or ether with the separation of the water.
  • an amount of lanolin is referred to herein, reference is made to the amount on a dry mass basis. Accordingly, as for tallow, whilst lanolin containing moisture can be used, the amount must be adjusted to provide comparable amounts of lanolin on a dry mass basis.
  • Fats are esters of fatty acids with glycerol having the general formula:
  • R 1 R 2 and R 3 may be the same fatty acid residue but, in general, the fats are mixed glycerols with each residue being different.
  • the fatty acids present in the greatest quantity are typically oleic, palmitic and stearic acid.
  • a number of fats (glycerols of fatty acids) occur naturally in plants and animals. Fats are generally seen as having a melting point of greater than 20°C at atmospheric pressure.
  • Oils There are glycerides of fatty acids as described for fats but having a melting point of less than 20°C at atmospheric pressure.
  • Vegetable Oil Vegetable oils are oils obtained from the leaves, fruit or seeds of plants.
  • Animal Oil Oils derived from animals.
  • Waxes Fatty acid esters with monohydric alcohols.
  • Fatty Acids Monobasic acids containing only the elements carbon, hydrogen and oxygen and consisting of an alkyl radical attached to the carboxyl group. Examples of fatty acids are palmitic acid, stearic acid, and linoleic acid.
  • Borates are salts of boric acid (H 3 BO 3 ). They typically contain either trigonal BO 3 or tetrahedral BO 4 either of which may be discrete or linked and in which additional hydroxyl groups may be linked to the boron.
  • Examples of borates are pyroborates and polyborates. Pyroborates such as Co 2 B 2 O 5 contain two BO 3 linked together through one oxygen. Polyborates contain infinite chains or rings, e.g. B 3 O 3 rings in [B 3 O 6 ] 3" metaborates or linear [BO 2 ] " in LiBO 2 .
  • the mould release composition of the present invention contains a boron component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof.
  • Borates are a family of ionic compounds containing negative ions consisting of boron and oxygen. They are usually formed from boric acid (H 3 BO 3 ) by dehydration and the simple borates contain 1 , 2, 3 of 4 boron atoms. Examples of borates include:
  • Dipotassium tetraborate K 2 (B 4 O )
  • Borax dipotassium tetraborate
  • the exact chemical formula of any borate will depend on the level of hydration of the borate compound.
  • disodium tetraborate (borax) may be present as Na 2 B O 7 (anhydrous), Na 2 B 4 O 7 .5H 2 O (pentahydrate) or Na 2 B 4 O .(10H 2 O) decahydrate.
  • reference to disodium tetraborate is intended to be a reference to the decahydrate and the amount of borate is calculated on this basis. As will be clear to a skilled addressee, however, different levels of hydration could be utilised that would provide the suitable amount of borate.
  • Poly borates are also well known in the art and can be used as the borate in the composition of the present invention.
  • the preferred borate to be used in the invention is borax as discussed above. It is preferred that it is used in the form of the decahydrate.
  • the exact amount of borate to be utilised will be dependent on the other ingredients in the composition.
  • the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably 0.002 to 0.5 moles of borate per litre of composition, even more preferably 0.006 to 0J moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 to 0.034 moles per litre of release agent.
  • Particularly preferred amounts are 0.033 moles, 0.26 moles, and 0.25 moles.
  • the preferred borate is disodium tetraborate. On a weight percentage, this corresponds to the amount of borate present in the composition being preferably in the range 0.07% to 19 wt.% (w/w), more preferably in the range 0.2% to 3.8 wt.%, even more preferably 0.2% to 1.9 wt.%, more preferably 0.75% to 1.5%, even more preferably 0.9% to 1.3% of the total weight of the mould release composition.
  • Borax is the common name for sodium tetraborate which has a varying chemical formula of Na 2 [B O ].XH 2 O wherein X can vary from 0 to 10 depending on the level of hydration of the borax.
  • Typical grades of commercially available borax include the anhydrous form (Na 2 B O 7 ), the pentahydrate
  • Borax is found to occur naturally as either kernite or tincal and it is also found to be present in the brines of Searle's Lake, United States of America. It has a number of uses including as a pesticide and has the advantage of not being very toxic to mammals. The anion is found to be strongly hydrogen bonded to water and the compound can be used as a source of boron compounds in applications requiring this. In addition, borax has a mild antiseptic property.
  • borax used in the present specification has been sourced from a solution of sodium tetraborate decahydrate in water.
  • any source of borax can be used.
  • suitable quantities of anhydrous disodium tetraborate (anhydrous) or disodium tetraborate pentahydrate could also be used to make up the solution. The important feature being that amounts used are equivalent to the total amount of anhydrous disodium tetraborate provided by the decahydrate.
  • the composition preferably contains 0.001 to 0.5 moles of borate per litre of composition, more preferably 0.002 to 0.5 moles of borate per litre of composition, more preferably 0.006 to 0.1 moles, even more preferably 0.006 to 0.05 moles, more preferably 0.02 to 0.04 moles, most preferably 0.024 to 0.034 moles per litre of release agent.
  • Particularly preferred amounts are 0.033 moles, 0.26 moles, and 0.25 moles.
  • the preferred borate is disodium tetraborate or a hydrate thereof.
  • this corresponds to the amount of borate present in the composition being preferably in the range 0.07% to 19 wt.% (w/w), more preferably in the range 0.2% to 3.8 wt.%, even more preferably 0.2% to 1.9 wt.%, more preferably 0.75% to 1.5%, even more preferably 0.9% to 1.3% of the total weight of the mould release composition.
  • the exact amount of borax to be used will depend on the application and the additional ingredients in the composition.
  • the mould release agents of the invention include a borate and one or more alcohols or polyols.
  • Alcohols and Polyols A number of alcohols or polyols can be used in the mould release compositions of the invention. In general, any compound containing a free hydroxy group can be used although it is preferred that the alcohol or polyol is a low molecular weight organic alcohol or polyol.
  • Preferred alcohols or polyols for use in the present invention are selected from the group consisting of glycol, glycerol, propylene glycol, and C ⁇ - 8 alcohols. It is further preferred that the alcohol is a diol and it is particularly preferred that the alcohol is glycerol or propylene glycol. Where an alcohol or polyol is present it is preferably present such that it represents at least 10 wt.% of the composition. It is particularly preferred that the alcohol is propylene glycol and is present at 10 wt.% of the composition.
  • the mould release composition contains a plurality of alcohols or polyols.
  • said alcohol or polyol is selected from the group consisting of propylene glycol, glycerol and glycol.
  • the mould release composition includes a borate and at least one organic component with a melting point below 100°C.
  • a number of organic compounds are suitable with preferred ones being selected from the group consisting of oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters or mixtures thereof.
  • Particularly preferred organic components are fats and oils with vegetable oils, tallow and lanolin being especially preferred.
  • the total amount of the additional organic components utilised (if at all) can vary significantly with the preferred range being from 10% to 70% (w/w). If a viscous product is required, the amount of additional organic component is preferably in the range from 18% to 55% by weight, more preferably 35 to 55%, most preferably 45% to 55%. When a less viscous composition is required, the amount of organic component is preferably present in the range 10% to 30%, more preferably 15% to 25%, most preferably 17.5% to 22.5%.
  • any vegetable oil may be used.
  • suitable vegetable oils are canola oil and linseed oil.
  • Canola oil is particularly preferred.
  • Canola oil is rape seed oil which has a low erucic acid content. Whilst it is preferred that the vegetable oil is a single oil, it may be a mixture of vegetable oils.
  • the mould release composition contains vegetable oil it is preferably present in the composition in an amount of 30% to 45% by weight of the composition. Particularly preferred amounts include 33.3%, 34.8%, 38.3% and 42.3%. It is preferred that the vegetable oil is recycled vegetable oil. In a particularly preferred embodiment, the vegetable oil is recycled, filtered vegetable oil. If vegetable oil is used, it is preferably heated at its boiling point for approximately five minutes prior to use in the production of a formulation of the invention.
  • tallow When tallow is present in the mould release composition, it is preferably present in an amount of from 9.8% to 35% by weight of the composition, more preferably 11.8% to 32% by weight of the composition, most preferably 14.8% to 17.8% by weight of the composition.
  • lanolin When lanolin is present in the composition in addition to other organic components, it is preferably present in an amount of from 0.5% to 7.5% by weight, more preferably 1.45% to 4.5% by weight, even more preferably 1.6% to 3.6%. If lanolin is the only organic component present, it is preferably present in the range of 30% to 60%, more preferably 40% to 50%, most preferably 44.2% by weight.
  • the component comprises vegetable oil and at least component selected from the growth consisting of lanolin and tallow. When the composition includes both tallow and vegetable oil, it preferably contains either:
  • the composition includes both lanolin and tallow. It is preferred that the total amount of lanolin and tallow in such composition is in the range 12% to 22% (more preferably 14% to 19%). In compositions containing both lanolin and tallow, it is preferred that the tallow is present in an amount of 10% to 18%, more preferably 11 % to 17%. It is preferred that the lanolin is present in these compositions in an amount of 1.45% to 4.5%, more preferably 1.6% to 3.6%.
  • the composition includes tallow, lanolin and vegetable oil.
  • compositions of the invention may therefore contain paraffin oils and the like as an example.
  • a particularly preferred additional ingredient is a water softening/emulsifying ingredient.
  • a preferred water softener is sodium carbonate. If present, it is preferably present in an amount of 0% to 2% by weight of the composition, more preferably 0.2% to 1.0%, preferably 0.2% by weight.
  • the composition may also contain sources of acid and alkali to adjust the pH to a suitable level if required. Suitable alkali sources are sodium hydroxide and potassium hydroxide. Suitable acid sources are mineral acids such as hydrochloric acid or sulphuric acid. In general, the source of alkali or acid is only required to adjust the pH of the composition to an appropriate pH in applications where pH control is important. It is preferred that the pH of the composition is in the range 6.0 to 10.0, more preferably 7.0 to 9.0, more preferably 8.0 to 9.0, most preferably about 8.5.
  • a particularly preferred composition is as follows: a) 0.6 parts to 3.6 parts borax (based on the decahydrate) b) 0 parts to 45 parts vegetable oil c) 10 parts to 25 parts tallow d) Balance water to 100 parts
  • compositions of the invention contain a certain amount of water.
  • the general compositions of the invention are produced by dissolving the appropriate boron-containing component in water. In circumstances where an organic component is required, the procedure varies slightly. In these cases, all organic components are blended (with heating if necessary) to produce a solution of the organic components. The solution is then preferably agitated rapidly with addition of an aqueous solution of the boron component being added at such a rate to ensure the temperature of the mixture stays constant, preferably within the range of 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. Upon completion of addition the mixture is stirred for a further 10 minutes at the temperature of addition and allowed to cool to ambient temperature. It can then be filtered if desired and packaged into the appropriate size containers.
  • the present invention in a further aspect relates to a method of improving the release of concrete from a surface, said method including the step of coating said surface with a composition of the invention (as described hereinbefore) prior to contacting said surface with concrete.
  • a composition of the invention as described hereinbefore
  • the composition can be used with any suitable surface used in shaping concrete with metallic, steel, wooden, plastic and concrete surfaces being particularly suitable. It is preferred that the surface is the surface of a mould.
  • the mould release compositions can be used in concentrated form as discussed above or can be diluted in part with water to form a less viscous emulsion if required.
  • the mould release composition can be coated onto the surface in a number of ways well known in the art.
  • the compositions may be sprayed onto the surface or applied by mop, brush/roller and are suitable for internal/external vibrating mould systems.
  • the application required is a thin film on the surface to be treated prior to contacting the surface with the pre-cured concrete blend.
  • the preferred thickness of the film is in the range of 0.25 micron to 1mm, preferably 0.25mm to 0.50 mm.
  • the mould release composition is applied by a spraying technique.
  • a spraying technique Such an application method has been found to produce a more uniform coating leading to improved results in the finished concrete article as well as superior mould release.
  • spraying techniques are found to be more economical in terms of the use of the material and the time taken to apply it.
  • compositions of the present invention it is noted that moderate- to-large over dosing does not cause detrimental effects of air entrapment/bug holes. There may however occur some compression of concrete in low regions of the mould. The appearance obtained typically shows uniform colour, which is also smooth to touch. This reduces finishing of the surface thus produced to be reduced to a bare minimum in contrast to available products.
  • the amount of time between application of the agent and the concrete can vary significantly however, it is found that the best results are achieved where the composition is applied to the surface immediately prior to the concrete being bought into contact with the surface.
  • the invention also relates to a method for producing a concrete article, said method including the steps of a) providing a mould for said concrete article; b) applying a mould release composition of the invention (as hereinbefore described) to said mould; c) bringing concrete into contact with said mould; d) allowing said concrete to cure; e) removing said concrete article from said mould.
  • moulds are suitable including wooden, steel, metallic, plastic or concrete moulds.
  • the moulds used are the moulds typically used in the art.
  • a number of mould shapes can also be utilized depending on the desired concrete article to be produced.
  • the process of the present invention has been found to be suitable for ornamental moulds with high levels of detail as required for garden ornaments and figurines for example, as well as for large, relatively straightforward moulds for beam construction.
  • the mould release composition can be applied in a number of ways well known in the art.
  • the compositions may be sprayed onto the mould or applied by mop, brush/roller and are suitable for internal/external vibrating mould systems.
  • the application required is a thin film on the surface to be treated prior to contacting the surface with the pre-cured concrete blend.
  • the preferred thickness of the film is in the range of 0.05 to 1mm, preferable 0.25mm.
  • the mould release composition is applied by a spraying technique.
  • spraying techniques are found to be more economical in terms of the use of the material and the time taken to apply the same.
  • a concrete formulation is then applied to said mould and allowed to cure.
  • the process of the invention has been found to be applicable to any number of concrete formulations known in the art.
  • the curing time will vary depending on the concrete composition chosen and will be within the skill of a skilled addressee to determine. Additives that increase this rate of cure may be incorporated in the concrete formulation and physical techniques that are known to facilitate curing, e.g. steaming, may also be used.
  • the concrete article is removed from the mould. As would be clear to a worker skilled in the art, there are a number of ways in which this can be achieved.
  • the invention provides a method of preparing a mould release composition, said method including the step of combining a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof with at least one organic component having a melting point below 100°C.
  • a boron containing component selected from the group consisting of boric acid, derivatives of boric acid, borates, derivatives of borates, and mixtures thereof and hydrates thereof with at least one organic component having a melting point below 100°C.
  • Preferred organic components are alcohols, polyols, oils, vegetable oils, animal derived oils, mineral oils, fats, animal derived fats, vegetable derived fats, fatty acids, animal derived fatty acids, vegetable derived fatty acids, fatty acid esters, animal derived fatty acid esters, vegetable derived fatty acid esters, glycerides, animal derived glycerides, vegetable derived glycerides, polyesters, animal derived polyesters, vegetable derived polyesters and mixtures and derivatives thereof. It is particularly preferred that the boron containing component is first dissolved in water to form an aqueous solution prior to combining it with the organic component.
  • said step of combining occurs at elevated temperatures, preferably between 50°C to 100°C, more preferably 70°C to 90°C, most preferably about 80°C. It is also preferred that said combining takes place with agitation, preferably sufficient agitation to produce an emulsion.
  • the following is a production procedure for the preferred mould release compositions of the invention.
  • the batch size is 1000 litres.
  • the organic compounds are admixed and if any of the components are not liquids at room temperature, the admixture is heated to provide a solution of the organic component(s).
  • the solution thus formed is agitated and the temperature increased to 80°C.
  • the solution of the boron containing component in water is added at a rate of approximately 10 litres per minute with constant stirring whilst maintaining the temperature at approximately 80°C (preferably between 70 - 90°C).
  • stirring is continued until the mixture reaches 80°C and agitated at this temperature for 10 minutes.
  • the mixture is then allowed to cool to ambient temperature, filtered and packed.
  • the admixture was allowed to stand at ambient temperature for 24 hours then diluted with stirring with equivalent quantities of water and the pH adjusted to be in the range 8-8.5.
  • the composition had the following physical properties.
  • EXAMPLE 3 The following ingredients were blended in order with mild heating and agitation. After each addition, the solution was allowed to equilibrate prior to the addition of the next ingredient. The time taken to reach equilibrium was typically of the order of 5-15 minutes for each addition.
  • Borax solution (2.4% w/v) 64.00%
  • Example 2 The composition of Example 2 was diluted with water to produce a composition having a water content of 60%.
  • This composition was applied as a thin film to a concrete mould prior to the concrete pour as a thin film. On removal of the concrete from the mould, the concrete surface was smooth to touch and displayed a uniform colour on the surface.
  • compositions listed in Table 2 were prepared using the method outlined in Example 1.
  • EXAMPLE 11 The following formulation was prepared using the procedure outlined in
  • Ondina oil is a paraffin oil.
  • a formulation was prepared using the procedure from Example 1 with the following composition:
  • a vegetable oil free formulation was prepared as follows:
  • Example 7 The product of Example 7 was applied to a panel mould for the production of concrete paving by a paint approach. A concrete mixture was then applied to the panel mould and allowed to cure, and removed from the mould. The article thus formed was found to have a smooth surface with no surface imperfections. The colour of the surface was the natural concrete colour. It was also notable that the moulds were easily stripped from the concrete and the surface thus produced was free of any bug holes and air entrapment.
  • Example 8 The composition of Example 8 was applied to the main shutter moulds of a "T" Beam. The mould was then filled with a concrete mixture and steam cured to facilitate rapid curing. Upon completion of curing, the mould was removed, leaving the completed beam.
  • the concrete surface was found to have produced a beam with a high class finish free of any surface imperfections.
  • the concrete surface was smooth to the touch and did not contain any bug holes or other surface imperfection. In addition, the colour of the surface was that of natural concrete.
  • the testers handling the composition found the composition easy to apply, was free of any nasal or eye irritation and facilitated demoulding of the beam upon curing.
  • Example 7 The composition of Example 7 was applied to a "baking tin" type mould.
  • the control agent used was an existing mineral oil. After application of the agents to the test and control moulds, a concrete formulation was poured into each mould and allowed to cure overnight. Upon completion of the curing time, the moulds were removed to produce the finished articles.
  • the trial product provided easy mould release and a product with no surface imperfections and was a natural colour.
  • the control mould had surface imperfections and bug holes noted.
  • Example 16 The products referred to in Example 16 were trialled again in "trough" shaped moulds.
  • the moulds were treated with the agents and then a concrete mixture was added.
  • a trough-shaped tap mould was added and vibrated to the finished mould position.
  • the concrete was allowed to cure overnight and removed from the mould.
  • the surface was found to be free from imperfections and to have a smooth, natural color. In contrast, the control product produced several surface imperfections.

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  • Engineering & Computer Science (AREA)
  • Manufacturing & Machinery (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)

Abstract

La présente invention concerne une composition de démoulage comprenant un composant qui contient du bore et est choisi dans le groupe formé par l'acide borique (B(OH)3), des dérivés d'acide borique, des borates, des dérivés de borates et des mélanges et des hydrates de ceux-ci. La présente invention concerne également l'utilisation de ces compositions dans des procédés pour retirer plus facilement du béton d'une surface et dans la production d'articles en béton. En outre, cette invention concerne des procédés de production de ces compositions.
PCT/AU2001/001211 2000-09-27 2001-09-27 Composition de demoulage WO2002026458A1 (fr)

Priority Applications (3)

Application Number Priority Date Filing Date Title
AU9349001A AU9349001A (en) 2000-09-27 2001-09-27 Mould release composition
AU2001293490A AU2001293490B2 (en) 2000-09-27 2001-09-27 Mould release composition
NZ524964A NZ524964A (en) 2000-09-27 2001-09-27 Mould release composition comprising a borate

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPR0409 2000-09-27
AUPR0409A AUPR040900A0 (en) 2000-09-27 2000-09-27 Mould release composition

Publications (1)

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WO2002026458A1 true WO2002026458A1 (fr) 2002-04-04

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AU (1) AUPR040900A0 (fr)
NZ (1) NZ524964A (fr)
WO (1) WO2002026458A1 (fr)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007053051A1 (fr) * 2005-11-03 2007-05-10 Oleg Leonidovich Kulikov Procede de traitement d'un materiau polymere thermoplastique au moyen d'une matrice revetue
EP1914054A1 (fr) * 2006-10-20 2008-04-23 Cognis IP Management GmbH Préparations additives pour produits de séparation en béton
FR2909918A1 (fr) * 2006-12-18 2008-06-20 Lafarge Sa Composition de demoulage pour materiaux a prise hydraulique
US7854803B1 (en) 2005-01-11 2010-12-21 Kirkpatrick William D Composition of materials and processes of making boroncitrates to establish set times for hydraulic cements
FR2967933A1 (fr) * 2010-11-30 2012-06-01 Lafarge Sa Composition de demoulage
US20160090543A1 (en) * 2013-05-20 2016-03-31 Malaysian Palm Oil Board Mould release lubricant
CN114085701A (zh) * 2021-11-23 2022-02-25 科之杰新材料集团有限公司 一种水性混凝土脱模剂及其制备方法

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JPS62297394A (ja) * 1986-06-18 1987-12-24 Deirekuto Sen Bou Kk 鍛造用離型潤滑剤
SU1715623A1 (ru) * 1990-02-27 1992-02-28 Конструкторско-Технологическое Бюро "Моспромстройматериалы" Композици дл обработки поверхности изделий
SU1731641A1 (ru) * 1990-10-18 1992-05-07 Полтавский Государственный Педагогический Институт Им.В.Г.Короленко Смазка дл форм
DE19822935A1 (de) * 1998-05-22 1999-11-25 Daimler Chrysler Ag Verfahren zum haftenden Aufbringen einer Schmierstoffschicht auf eine freiliegende und triologisch beanspruchte Oberfläche eines Formwerkzeuges, insbesondere eines Umformwerkzeuges wie Tiefziehpressen und dgl. sowie Formwerkzeug mit auf seiner freiliegenden Oberfläche haftenden Schmierstoffschicht
AU5945499A (en) * 1998-11-19 2000-05-25 Superior Graphite Co. High temperature, water-based lubricant and process for making the same

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JPS62297394A (ja) * 1986-06-18 1987-12-24 Deirekuto Sen Bou Kk 鍛造用離型潤滑剤
SU1715623A1 (ru) * 1990-02-27 1992-02-28 Конструкторско-Технологическое Бюро "Моспромстройматериалы" Композици дл обработки поверхности изделий
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DE19822935A1 (de) * 1998-05-22 1999-11-25 Daimler Chrysler Ag Verfahren zum haftenden Aufbringen einer Schmierstoffschicht auf eine freiliegende und triologisch beanspruchte Oberfläche eines Formwerkzeuges, insbesondere eines Umformwerkzeuges wie Tiefziehpressen und dgl. sowie Formwerkzeug mit auf seiner freiliegenden Oberfläche haftenden Schmierstoffschicht
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Cited By (13)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7854803B1 (en) 2005-01-11 2010-12-21 Kirkpatrick William D Composition of materials and processes of making boroncitrates to establish set times for hydraulic cements
US7892351B1 (en) 2005-01-11 2011-02-22 Kirkpatrick William D Composition of materials and processes for making boroncitrates to create cements with field adjustable set times
WO2007053051A1 (fr) * 2005-11-03 2007-05-10 Oleg Leonidovich Kulikov Procede de traitement d'un materiau polymere thermoplastique au moyen d'une matrice revetue
EP1914054A1 (fr) * 2006-10-20 2008-04-23 Cognis IP Management GmbH Préparations additives pour produits de séparation en béton
US8080103B2 (en) 2006-12-18 2011-12-20 Lafarge Demoulding composition
WO2008087298A1 (fr) 2006-12-18 2008-07-24 Lafarge Composition de demoulage
FR2909918A1 (fr) * 2006-12-18 2008-06-20 Lafarge Sa Composition de demoulage pour materiaux a prise hydraulique
FR2967933A1 (fr) * 2010-11-30 2012-06-01 Lafarge Sa Composition de demoulage
WO2012072922A1 (fr) * 2010-11-30 2012-06-07 Lafarge Composition de demoulage
US20160090543A1 (en) * 2013-05-20 2016-03-31 Malaysian Palm Oil Board Mould release lubricant
US9809776B2 (en) * 2013-05-20 2017-11-07 Malaysian Palm Oil Board Mould release lubricant
CN114085701A (zh) * 2021-11-23 2022-02-25 科之杰新材料集团有限公司 一种水性混凝土脱模剂及其制备方法
CN114085701B (zh) * 2021-11-23 2022-07-05 科之杰新材料集团有限公司 一种水性混凝土脱模剂及其制备方法

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NZ524964A (en) 2003-08-29

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